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Topic: noooooooooo (Read 1088 times)

So today I finally got my bike back together after dumping the hump and putting on an 18 tooth sprocket and replacing the clutch plates.

I started it and nooooooo.....ATF leaking out of the primary case behind the clutch basket (a pretty sizable one at that). What did I do wrong? Obviously I'm gonna have to go back in there. My best guess is the oil seal behind the clutch (part 111888). Could it be anything else? I'm at a loss; the oil seal looked good when put it on the new primary.

The typical procedure is to cover the splines with electrical tape or something like that, before you pull the inner primary case. That protects the seal from lip damage by the splines.Leave the tape on the splines until after you put the inner primary case back on.

Then hopefully, the seal will be undamaged, and won't leak.It's not that bad to have to go back and re-do that. It gives you a little practice.

Ace is correct on fitting the cover. But was wondering did you change the seal itself? If you did you have to be sure you've got the right seal. The 4@5 speed are different sizes and bolt on the same. A five speed will leak like crazy on a four speed shaft. ERC

I did change the seal yes. And it does leak like crazy. It came in the hitchock set for an ES to KS conversion. Since there are so few 4sp e-starts could this be the problem? (right? 2003 was the first year for e-start and later in the year 5-spead gearbox was introduced). In that case I may have put on a 5 speed oil seal. I ordered a new one from nfield gear, part 111888 let me make sure that is the right one.

I got a kit from Hitchcocks. I have a 2005 and there was some problems, my bike had a bolt to the rear which holds everything steady,there is no hole in the rear of the new case to secure it also there was an extra hole in the case that had to be filled. My mechanic has managed to make a shim to stop the case moving when you change gears and stop the leak.

The 5 speed seal # is 550116 the 4 speed is 111888. Thet both fit the cover the same way. Easy to confuse them there is very little difference between them. I put a 4sp in a 5sp years ago it didn't leak but made it shift crummy. ERC

Thanks again ERC, part 111888 ordered. Also -- and this may be painfully obvious -- the gasket goes between the oil seal and the inner primary case, correct? I mistakenly didn't note it when taking it apart. Should I use gasket sealant? Sorry, I'm new to all this....my first big job. My mechanic friend told me to mentally prepare to do everything twice (as it is my first go at all this), apparently he was right!

I wonder did you centralise the seal to the mainshaft after the inner case was finally bolted in place? (Before fitting the clutch). There is some slack in the seal bolt holes for this to be done. Just a thought!

I did. The seal was put in after the case was bolted on and checked twice for tightness. Gonna really have to pay attention to details the second time around cause I'm not doing this three times! Thanks for all the help. Just posting about this stuff makes me feel better.